Global Manpower Development

797F off-highway truck

Air System
Module 4 - Text Reference

SERV1872

797F Off-Highway Truck

Module 4 - Air System
Text Reference

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© 2009 Caterpillar Inc.

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SERV1872 - 11/09 -2- Module 4 - Air System

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Air System

• Air system components: The air system on the 797F Off-Highway Trucks controls the air start motor, the
autolube system, and the air horn.
1. Compressor
2. Air reservoirs This illustration shows the location of the main air system components. The air
3. Air dryers system components are:
4. Air horn
-- compressor (1)
5. Air start motor
-- air reservoirs (2)
6. Autolube tank
-- air dryers (3)
-- air horn (4)
-- air start motor (5)
-- autolube tank (6)

© 2009 Caterpillar Inc.

SERV1872 - 11/09
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• Air system components:
1. Air compressor
2. Governor assembly
3. Air dryers
4. Air dryer switching module
5. Pressure protection valve
6. Air reservoirs
7. Air start solenoid valve
8. Air horn solenoid valve
9. Air system pressure sensor
-3- Module 4 - Air System
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The air compressor (1) is driven by the engine and provides the air flow. The air
compressor is lubricated with engine oil and cooled by the engine coolant. The
governor assembly (2) maintains the air system pressure and can be adjusted with
a screw below the governor cover.
Air flows from the compressor to the air dryers (3). The air dryers remove contaminants
and moisture from the air system. The air dryer desiccant serviceability has improved.
The desiccant can be serviced on the truck by removing one bolt and a cover. It is
not necessary to remove the air dryer assembly as on the 797B truck.
Air flows from the air dryers to the air dryer switching module (4), the pressure protection
valve (5), and the air reservoirs (6). The air dryer switching module alternates control
pressure between the air dryer assemblies. The pressure protection valve provides
a backup for the check valve located in the air reservoir.
From the air reservoirs air flows to the air start solenoid valve (7), the air horn
solenoid valve (8), the autolube solenoid valve (not shown), and the air system
pressure sensor (9).
The air pressure sensor sends a signal to the Chassis ECM indicating system air
pressure. The air start solenoid valve directs air to the starter motor to start the
engine. The air horn solenoid valve directs air to sound the air horn. The autolube
solenoid valve directs air to activate the autolube system.
© 2009 Caterpillar Inc.
SERV1872 - 11/09 -4- Module 4 - Air System

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• Autolube solenoid valve (arrow) The autolube solenoid valve (arrow) is located on top of the grease tank. The
autolube solenoid valve directs air to activate the autolube system.

© 2009 Caterpillar Inc.

SERV1872 - 11/09 -5- Module 4 - Air System

(3) Air Dryer

(19) External 797F AIR SYSTEM

Air Supply
SCHEMATIC
(4) Air Dryer
Switching Module
(18)
Unloader (3) Air Dryer
Valve
(2) Compressor (5) Pressure
Group Protection Valve

(6) Governor
Assembly
(9) Drain
Valve
(1)
Reservoir (7) Check Valve

(17)
(15) Air Start Motor Autolube

(1)
Reservoir (8) Relief
Valve
(11) Air Horn
Solenoid Valve
(12) Autolube
Solenoid
(13) Valve
(10) Air Start Air System
Solenoid Pressure (16) Air
(14) Air Start Sensor Horn
Relay Valve

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• Air flow This schematic shows air flow through the air system with the air reservoirs (1)
charged. The air flows from the air compressor (2), through the air dryers (3), to the
air dryer switching module (4), the pressure protection valve (5), and the air
reservoirs.

• Air compressor The air compressor provides the air flow. The governor assembly (6) maintains a
system air pressure between approximately 655 kPa (96 psi) and 827 kPa (120 psi).
The governor pressure setting can be adjusted with a screw below the governor
cover. Pilot air flows from one of the reservoirs to the governor assembly. When the
pressure is approximately 827 kPa (120 psi), the governor spool shifts downward
and the top envelope directs air flow to the dump valve in the air compressor, which
relieves the system pressure. The air compressor is lubricated with engine oil and
cooled by the engine coolant.

• Air dryer Air flows from the compressor to the air dryers. The air dryers remove contaminants
and moisture from the air system. The condition of the air dryers should be checked
regularly and the desiccant changed periodically, depending on the humidity of the
local climate. Air flows from the air dryers to the air dryer switching module and the
pressure protection valve. The air dryer switching module receives 24 volts. When
system pressure reaches 482 kPa (70 psi), the air dryer switching module starts and
opens a purge port to one of the air dryers every 30 seconds. The switching module
alternates control pressure between the air dryer assemblies.

© 2009 Caterpillar Inc.

SERV1872 - 11/09
• Switching module
• Pressure protection valve
• Air reservoir
• Air start solenoid valve
• Air pressure sensor
• Key start switch ON
• Air horn solenoid valve
• Autolube solenoid valve
-6- Module 4 - Air System
When supply pressure at the air dryer control module decreases below 482 kPa
(70 psi), the switching module stops the air purge cycle. Supply pressure decreases
below 482 kPa (70 psi) at the air dryer control module after the air compressor
governor cuts out and air system pressure drops below the air compressor governor
cut-in setting. When the air compressor cuts in, the air dryer control module will start
the air dryer purge cycle again when 621 kPa (90psi) air supply pressure is present
at the pressure protection valve.
The switching module provides a continuous air drying capability, as long as the key
is ON and the air supply pressure is at least 482 kPa (70 psi).
NOTE: For additional information on the air dryer, refer to the System Operations
“Air Dryer For Vehicle Air Systems” SENR7474.
The pressure protection valve opens at 550 kPa (80 psi) and closes at 482 kPa (70
psi). The pressure protection valve provides a backup for the check valve located on
the air tank. Air flows through the pressure protection valve and the check valve and
fills the air tank. The check valve prevents a loss of air in the tank if the air dryer, the
air dryer control module, or the pressure protection valve require service.
The air flows from the air dryer through the pressure protection valve and a check
valve (7) to the air reservoirs. The check valve prevents a loss of air if a leak upstream
of the reservoir occurs. A relief valve (8) is installed on the air reservoir, which opens
at approximately 1035 kPa (150 psi). Also, installed on the reservoir is the drain
valve (9). The drain valve is used to remove the air or any condensation from the
reservoir at temperatures below 0° C and (32° F).
From the reservoirs, air flows to the air start solenoid valve (10), the air horn solenoid
valve (11), the auto lube solenoid valve (12), the air system pressure sensor (13),
and the governor.
The air pressure sensor sends a signal to the Chassis ECM indicating system air
pressure.
When the key start switch is turned to the start position, the air start solenoid valve is
energized and the air start relay valve (14) shifts to the left. Air is directed to the air
start motors (15) and the motor engages. When the engagement is complete, the air
pressure on the air start relay valve shifts the air start relay valve to the left and air
flow from the air reservoirs is directed to the air start motors. The air start motors
rotate the engine flywheel to start the engine.
The air horn solenoid valve directs air to sound the air horn (16).
The autolube solenoid valve directs air to activate the autolube system (17).
© 2009 Caterpillar Inc.